Oxygen sensor for multiple port applications

Abstract

A sensor comprising; a sensing element disposed within a housing having a lower shell portion, a middle shell portion, and an upper shell portion, wherein said sensing element extends from said lower shell portion through at least a portion of said middle shell portion; a connector plug concentrically disposed within said upper shell portion; one or more electrical wires extending from said connector plug through an opening in said upper shell portion, and said opening forming a seal in said upper portion concentrically disposed around said one or more eletrical wires.

What is claimed is:  
     
       1. A sensor, comprising: 
       a sensing element disposed within a single piece housing having a lower shell portion, a middle shell portion, and an upper shell portion, wherein said sensing element extends from said lower shell portion through at least a portion of said middle shell portion;  
       a connector plug disposed within said upper shell portion in electrical connection with said sensing element;  
       one or more electrical wires extending from said connector plug and through an opening in said upper shell portion; and  
       a seal formed between said opening and said one or more wires by interior engagement between said single piece housing defining said opening and a periphery of said one or more wires.  
     
     
       2. A sensor according to  claim 1 , wherein said seal is formed when upper shell portion is crimped to form said opening and engage said one or more wires. 
     
     
       3. A sensor according to  claim 1 , wherein said housing comprises inconel sheet metal. 
     
     
       4. A sensor according to  claim 1 , wherein said housing comprises a ferrous material selected from high chrome steel, nickel stainless or mixture thereof. 
     
     
       5. A sensor according to  claim 1 , wherein said on e or more electrical wires includes thermocouple wires. 
     
     
       6. A sensor according to  claim 1 , further comprising insulating material disposed between said sensing element and said middle shell portion. 
     
     
       7. A sensor according to  claim 1 , wherein said opening formed in said upper shell portion of said single piece housing is adaptable to form said seal. 
     
     
       8. A sensor according to  claim 6 , wherein said insulating material is a talc pack. 
     
     
       9. A sensor according to  claim 6 , wherein said insulating material is selected from the group consisting of polymers, ceramics, or a mixture comprising at least one of the foregoing. 
     
     
       10. A sensor according to  claim 8 , wherein said insulating material is compressed towards said lower shell portion and is retained by a press ring engaged between the sensing element and the middle shell portion. 
     
     
       11. A sensor according to  claim 10 , wherein said press ring frictionally engages the sensing element and the middle shell portion; said press ring further comprising barbs to prevent movement thereof. 
     
     
       12. A sensor according to  claim 10 , wherein said insulating material is compressed towards said lower shell portion against a grounding gasket that electrically engages the sensing element and a shoulder formed in said middle shell portion of said housing. 
     
     
       13. A sensor according to  claim 1 , wherein said seal is formed by crimping said upper shell portion of said single piece housing forming said seal between said opening and insulation of said one or more wires defining a periphery of said one or more wires.